COURSE OVERVIEW:

Precision alignment is the single most important factor in extending the mean time between failures for pumping systems. This course provides a technical deep dive into the methodologies used to ensure that the rotational axes of the pump and its driver are perfectly collinear. Participants will explore the physics of misalignment and its destructive effects on bearings, mechanical seals, and couplings, gaining a clear understanding of why precision is mandatory for modern high-speed machinery.

The scope of this training encompasses the full spectrum of alignment tools, from traditional straightedge and feeler gauge methods to advanced laser-based systems and dial indicator techniques. We will analyze the "rim and face" method and the "reverse indicator" method in detail, providing participants with the mathematical foundation and practical skills to perform these tasks in the field. The course also addresses the critical preparation steps, such as soft foot detection and baseplate stabilization, which are often overlooked but essential for a successful alignment.

Coverage includes the management of thermal growth, where participants learn how to calculate and apply offsets to account for the changes in machinery position during operation. The course emphasizes a structured approach to alignment, teaching attendees how to document results and verify that the final tolerances meet or exceed manufacturer specifications. By mastering these precision techniques, participants will be able to significantly reduce vibration, lower energy costs, and improve the overall reliability of their plant's rotating assets.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the different types of misalignment: Offset, Angular, and Skew.
• Execute a comprehensive soft foot check and correction procedure.
• Demonstrate the "Reverse Dial Indicator" method for shaft alignment.
• Perform precision alignment using modern laser alignment systems.
• Calculate thermal growth compensations for hot-service pumps.
• Interpret alignment tolerances based on rotational speed and coupling type.
• Identify the mechanical symptoms of chronic misalignment in pumps.
• Utilize the "Rim and Face" method for large diameter couplings.
• Assess the condition of baseplates and foundations before alignment.
• Apply correct shimming techniques to achieve stable machine positioning.
• Eliminate piping strain and its negative impact on pump alignment.
• Document alignment readings and final results for maintenance records.
• Troubleshooting common errors in laser alignment sensor setup.
• Justify the return on investment for precision alignment programs.

TARGET AUDIENCE:

Maintenance Technicians, Millwrights, Mechanical Engineers, Supervisors, and Reliability Specialists responsible for the installation and maintenance of pumps and drivers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.